Motor stator automatically assembling method

ABSTRACT

A motor stator automatically assembling system includes a feeding unit, a wire-winding unit, a first conveyer unit, a second conveyer unit, a first assembly unit and a second assembly unit. The feeding unit is operated to feed a plurality of insulation members. The insulation members are arranged on the first conveyer unit to be conveyed to the wire-winding unit. The wire-winding unit is operated to wind wires on the insulation members to form a plurality of wire-wound insulation members. The wire-wound insulation members are arranged on the second conveyer unit to be conveyed to the first assembly unit. The first assembly unit is operated to insert pole teeth into the wire-wound insulation members to form a plurality of compact pole tooth sets. The second assembly unit is operated to combine the compact pole tooth sets with a stator ring frame to form an assembled motor stator.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a motor stator automatically assemblingsystem, assembly line and assembling method thereof. More particularly,the present invention relates to the motor stator automatically andcontinuously assembling system, assembly line and assembling methodthereof

2. Description of the Related Art

Taiwanese Patent Application Publication No. 201220649, entitled “MotorStator and Assembling Method Thereof,” discloses a motor statorincluding a stator unit and an auxiliary inductive unit. The stator unitincludes a PCB substrate and a plurality of inductive coils which areequi-spaced apart and embedded in the PCB substrate. The auxiliaryinductive unit includes an insulation member, a magnetically conductivemember and at least one winding set. The insulation member is arrangedon the PCB substrate, and the magnetically-conductive member is arrangedon the insulation member. The winding is combined with the magneticallyconductive member, the insulation member and the PCB substrate. Thewinding includes a pillar member and an auxiliary coil wound thereon.The pillar member extends through the magnetically conductive member,the insulation member and the PCB substrate. The pillar member with theauxiliary coil wound thereon protrudes into the PCB substrate toincrease the number of total turns of each coil or the total number ofpoles deployed on the stator unit, thereby improving the magneticallydriving force of the motor stator.

However, the assembling method of the motor stator applied in TWN PatentAppl. Pub. No. 201220649 is not an automatically assembling method.Hence, there exists a need of providing an automatically assemblingmethod for the conventional motor stator. The above-mentioned patent isincorporated herein by reference for purposes including, but not limitedto, indicating the background of the present invention and illustratingthe state of the art.

As is described in greater detail below, the present invention providesa motor stator automatically assembling system and method thereof. Aplurality of automatic assembly units and a plurality of conveyer unitsare provided in an assembly line to automatically assemble and conveymotor stator components to form an assembled motor stator in such a wayto mitigate and overcome the above problem.

SUMMARY OF THE INVENTION

The primary objective of this invention is to provide a motor statorautomatically assembling system and method thereof. A plurality ofautomatic assembly units and a plurality of conveyer units are connectedto form an automatically assembly line along which to automaticallyassemble motor stator components step by step for forming asemi-assembled motor stator to a completely-assembled motor stator.Accordingly, the motor stator automatically assembling system and methodof the present invention are successful in providing an automaticallymanufacturing process of the motor stator.

The motor stator automatically assembling method in accordance with anaspect of the present invention includes the steps of:

selecting and feeding insulation members by a feeder unit and a vibratorunit;

supplying and arranging the insulation members on a first conveyer unitwhich conveys the insulation members to a wire-winding unit;

winding at least one wire on the associated insulation member to formwire-wound insulation members by the wire-winding unit;

supplying and arranging the wire-wound insulation members on a secondconveyer unit which conveys the wire-wound insulation members to a firstassembly unit;

inserting pole teeth into the wire-wound insulation members to form aplurality of compact pole tooth sets by the first assembly unit; and

inserting the compact pole tooth sets into a predetermined stator ringframe to form a semi-assembled motor stator by a second assembly unit.

In a separate aspect of the present invention, the motor statorautomatically assembling method further includes the step of: prior toselecting and feeding the insulation members, inserting at least one pinin the insulation member by a pin insert unit.

In a further separate aspect of the present invention, the motor statorautomatically assembling method further includes the step of: whilewinding wires on the insulation members, further winding the wires onthe associated pin to electrically connect therewith.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps of:moistening the pins of the wire-wound insulation members with solderpaste, soldering the pins with the wires, bending the pins to form abent portion, and executing an impedance or insulation test on thewire-wound insulation members by a first test equipment and combinationthereof.

In yet a further separate aspect of the present invention, the poleteeth are provided in a feed magazine from which the stacked pole teethare inserted into the wire-wound insulation members.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps of:supplying the stator ring frame to the second assembly unit by a thirdconveyer unit.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps of:rotating the stator ring frame with respect to the second assembly unitby a rotary unit, thereby inserting each of the pole tooth sets into thestator ring frame.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps of:inserting the pins of the semi-assembled motor stator in a printedcircuit board, thereby combining the semi-assembled motor stator withthe printed circuit board to form a complete-assembled motor stator, andfurther bending the pins, moistening the pins with solder paste andsoldering the pins with the printed circuit board.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps ofpunching at least one surface of the semi-assembled motor stator to format least one recession which is formed to combine the pole teeth to eachother or to combine the pole tooth sets with the stator ring frame toreinforce the structure of the semi-assembled motor stator.

In yet a further separate aspect of the present invention, the motorstator automatically assembling method further includes the steps ofexecuting a power test, a resistance test, a dielectric withstandvoltage test, an insulation shock test or a load test on thecomplete-assembled motor stator by a second test equipment.

The motor stator automatically assembling system in accordance withanother aspect of the present invention includes:

a feeder unit provided to feed a plurality of insulation members;

a first conveyer unit connecting to the feeder unit to receive theinsulation members therefrom, with the first conveyer unit operated toarrange the insulation members thereon and to convey the insulationmembers from the feeder unit;

a wire-winding unit connecting to the first conveyer unit to receive theinsulation members therefrom, with the wire-winding unit operated towind wires on the insulation members to form a plurality of wire-woundinsulation members;

a second conveyer unit connecting to the wire-winding unit to receivethe wire-wound insulation members therefrom, with the second conveyerunit operated to arrange the wire-wound insulation members thereon andto convey the wire-wound insulation members from the wire-winding unit;

a first assembly unit connecting to the second conveyer unit to receivethe wire-wound insulation members therefrom, with the first assemblyunit operated to insert pole teeth into the wire-wound insulationmembers to form a plurality of compact pole tooth sets; and

a second assembly unit operated to insert the compact pole tooth setsinto a predetermined stator ring frame to form a semi-assembled motorstator.

In a separate aspect of the present invention, the feeder unit furtherincludes a vibrator unit which is operated to select the insulationmembers prior to feeding.

In a further separate aspect of the present invention, a pin insert unitis operated to insert at least one pin in the insulation member.

In yet a further separate aspect of the present invention, a thirdconveyer unit is connected between the first assembly unit, and thesecond assembly unit, with the third conveyer unit operated to conveythe compact pole tooth sets to the second assembly unit.

In yet a further separate aspect of the present invention, a fourthconveyer unit is operated to convey the stator ring frame to the secondassembly unit.

In yet a further separate aspect of the present invention, a solderingunit is operated to solder the pins to form a plurality of coil sets.

In yet a further separate aspect of the present invention, a first testequipment unit is operated to execute an impedance or insulation test onthe wire-wound insulation members.

In yet a further separate aspect of the present invention a second testequipment unit is operated to execute a power test, a resistance test, adielectric withstand voltage test, an insulation shock test or a loadtest on the complete-assembled motor stator.

Further scope of the applicability of the present invention will becomeapparent from the detailed description given hereinafter. However, itshould be understood that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various modifications willbecome apparent to those skilled in the art from this detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus are not limitativeof the present invention, and wherein:

FIG. 1 is a flow chart of a motor stator automatically assembling methodin accordance with a preferred embodiment of the present invention.

FIG. 1A is a block of a motor stator automatically assembly line inaccordance with a preferred embodiment of the present invention.

FIGS. 2A and 2B are fragmentally schematic views of first and secondportions of a motor stator automatically assembling system in accordancewith a preferred embodiment of the present invention.

FIG. 3 is a schematic view of an insulation member applied in thepresent invention.

FIG. 4 is a schematic view of the wire-wound insulation membermanufactured by the motor stator automatically assembling system andmethod in accordance with the preferred embodiment of the presentinvention.

FIG. 5 is a schematic view of compact pole tooth sets assembled by themotor stator automatically assembling system and method in accordancewith the preferred embodiment of the present invention.

FIG. 5 a is a schematic cross-sectional top view of a feed magazine andstacked pole teeth provided therein applied in the present invention.

FIG. 6 is a schematic view of a stator ring frame applied in the presentinvention.

FIG. 7 is a schematic view of a semi-assembled motor stator assembled bythe motor stator automatically assembling system and method inaccordance with the preferred embodiment of the present invention.

FIG. 8 is a schematic view of a printed circuit board applied in thepresent invention.

FIG. 9 is a schematic view of a complete-assembled motor statormanufactured by the motor stator automatically assembling system andmethod in accordance with the preferred embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

It is noted that a motor stator automatically assembling system andmethod in accordance with the preferred embodiments of the presentinvention are suitable for assembling and testing various motor statorsteps, for example: inner or outer stator assembling steps, which arenot limitative of the present invention. The motor stator automaticallyassembling system and method in accordance with the preferred embodimentof the present invention are suitably implemented by utilizing variousautomatic apparatus, for example: auto pin insert machines, autoconveyers, auto wire-winding machines, auto punch machines, auto testingequipments and combinations thereof, which are not limitative of thepresent invention.

Referring to FIGS. 1, 1A, 2A and 2B, the motor stator automaticallyassembling method, as shown in FIG. 1, in accordance with a preferredembodiment of the present invention includes eight steps correspondingto the motor stator automatically assembling system, as best shown inFIGS. 2A and 2B, or the assembly line, as best shown in FIG. 1A. Turningnow to FIG. 3, an isolation member or the like (e.g. isolation jacket orbobbin member) is applied to execute an automatically assembling methodin accordance with the present invention.

Referring to FIGS. 1, 2A and 3, the motor stator automaticallyassembling method in accordance with the preferred embodiment of thepresent invention includes the step S1: automatically inserting at leastone pin 101 in each predetermined side position of insulation members(e.g. isolation jacket) 10 by a pin insert unit (e.g. pin insertmachine) 1, thereby automatically supplying the insulation members 10therefrom. Each of the insulation members 10 has a central hole and awire-winding recess formed therearound, as best shown in FIG. 3.

Still referring to FIGS. 1, 2A and 3, the motor stator automaticallyassembling method in accordance with the preferred embodiment of thepresent invention includes the step S2: automatically selecting andfeeding the insulation members 10 by a feeder unit (e.g. feeder machine)2 and a vibrator unit (e.g. vibrator machine) 2 a connected therewith,thereby feeding the insulation members 10 into an assembly line andselecting the unqualified insulation members 10. The insulation members10 received from the pin insert unit 1 are automatically conveyed by thefeeder unit 2 to the vibrator unit 2 a.

With continued reference to FIGS. 1, 2A and 3, the motor statorautomatically assembling method in accordance with the preferredembodiment of the present invention includes the step S3: automaticallysupplying and arranging the insulation members 10 in order on a firstconveyer unit (e.g. a pair of automatically reciprocated slides) 3 whichis operated to automatically convey the insulation members 10 from thepin insert unit 1 or the vibrator unit 2 a to an auto wire-winding unit(e.g. multi-winding machine) 4. By way of example, the insulationmembers 10 are automatically arranged in order on positioning seats ofthe first conveyer unit 3 and are further conveyed along a track to apredetermined position (e.g. the auto wire-winding unit 4) to process aprocedure of wire-winding, soldering, testing and other processing.

FIG. 4 shows a schematic view of the wire-wound insulation membermanufactured by the motor stator automatically assembling system andmethod, as best shown in FIGS. 1 and 2A, in accordance with thepreferred embodiment of the present invention. Referring to FIGS. 1, 2A,3 and 4, the motor stator automatically assembling method in accordancewith the preferred embodiment of the present invention includes the stepS4: automatically winding wires 102 on the wire-winding recesses of theassociated insulation members 10 to form a plurality of wire-woundinsulation members 10 with windings by the wire-winding unit 4. By wayof example, a wire array seat 4 a is provided with the wire-winding unit4 to supply a plurality of the wires 102 thereto for the wire-windingoperation.

With continued reference to FIGS. 1, 2A, 3 and 4, by way of example,while or after automatically winding the wires 102 on the insulationmembers 10, the wires 102 are further automatically wound on theassociated pin 101 to electrically connect therewith. Accordingly, theentire wire-winding process shall be simplified by reducing a separatewire-winding or binding process of the wire 102 with the pin 101.

Turning now to FIGS. 2A and 2B, by way of example, the wire-woundinsulation members 10 are automatically extracted from the wire-windingunit 4, as best shown in FIG. 2A, are arranged in order on positioningseats of a second conveyer unit 3′ (or rearranged on the first conveyerunit 3) and are further conveyed along the track to a first testingequipment 5 or a predetermined position (e.g. auto soldering unit) toprocess a procedure of solder-paste-wetting, soldering or pin-bending.The first testing equipment 5 is used to execute an impedance orinsulation test on the wire-wound insulation members 10.

Referring again to FIGS. 1, 2B and 4, the motor stator automaticallyassembling method in accordance with the preferred embodiment of thepresent invention includes the step S5: automatically supplying andarranging the wire-wound insulation members 10 on a third conveyer unit(e.g. conveyer belt) 6 which is operated to convey the wire-woundinsulation members 10 to a first assembly unit 6 a and a second assemblyunit 7. By way of example, the wire-wound insulation members 10 areautomatically extracted from the first testing equipment 5 by amanipulator unit 5 a and are further deployed on the third conveyer unit6 by an air piston. The third conveyer unit 6 further includes avibrator unit operated to convey the wire-wound insulation members 10.

FIGS. 5 and 5 a are schematic views of compact pole tooth sets andstacked pole teeth provided in a feed magazine applied in the presentinvention. Referring to FIGS. 1, 2B, 5 and 5 a, the motor statorautomatically assembling method in accordance with the preferredembodiment of the present invention includes the step S6: automaticallyinserting a single pole tooth or stacked pole teeth 201 into the centralholes of the wire-wound insulation members 10 in a manner of fitting toform a plurality of the compact pole tooth sets by the first assemblyunit 6 a. Accordingly, after assembled, the compact pole tooth sets areapplied to generate magnetic fields to electrically drive a motor rotor,not shown in drawings. By way of example, each of the pole teeth 201 hasa pole pillar, an engaging portion and a pole face, as best shown inFIG. 5 a.

Referring again to FIGS. 1, 2B, 5 and 5 a, by way of example, the firstassembly unit 6 a has eight or more sets of pole tooth storage units(e.g. feed magazine with magazine spring) 202 which are arranged in acircular member of the first assembly unit 6 a. Each set has four poletooth storage units 202 which are equi-spaced apart, as best shown inFIG. 2B. In assembling operation, the pole teeth 201 are fittinglyinserted into the central holes of the wire-wound insulation members 10.

FIG. 6 shows a schematic view of a stator ring frame applied in thepresent invention corresponding to stator ring frames 20 shown in FIG.2B. FIG. 7 shows a schematic view of a semi-assembled motor statorformed by the stator ring frame, as best shown in FIG. 6, in accordancewith the preferred embodiment of the present invention. Referring againto FIGS. 1, 2B, 6 and 7, the motor stator automatically assemblingmethod in accordance with the preferred embodiment of the presentinvention includes the step S7: automatically inserting at least one ora plurality of the compact pole tooth sets into the stator ring frame 20to form a semi-assembled motor stator 100 by the second assembly unit 7.By way of example, the third conveyer unit 6 is provided to convey thecompact pole tooth sets to the second assembly unit 7 or is selectivelyomitted.

With continued reference to FIG. 6, by way of example, the stator ringframe 20 can be selected from an outer stator ring frame or an innerstator ring frame. Furthermore, the second assembly unit 7 includes afourth conveyer unit 7 a which is operated to convey the stator ringframe 20 to the second assembly unit 7 or may be omitted. The secondassembly unit 7 includes a rotary server unit (e.g. 12-station rotaryserver unit) which is applied to rotate the stator ring frame 20 forinserting each of the compact pole tooth sets into engaging portions ofthe stator ring frame 20.

Referring again to FIGS. 2B and 7, by way of example, the motor statorautomatically assembling method in accordance with the alternativeembodiment of the present invention further includes the step:automatically punching at least one surface of the semi-assembled motorstator 100 by a punch machine 8 to form a plurality of recessions “A”which are formed to combine the pole teeth 201 to each other or tocombine the compact pole tooth sets with the stator ring frame 20 toreinforce the structure of the semi-assembled motor stator 100. Thepunch machine 8 further includes a rotary unit (e.g. manipulator) 8 awhich is applied to turn the semi-assembled motor stator 100 over forthe punching operation.

FIG. 8 shows a schematic view of a printed circuit board 30 attached toa side of the semi-assembled motor stator 100 shown in FIG. 7. FIG. 9shows a schematic view of the printed circuit board 30, as best shown inFIG. 8, attached to a side of the semi-assembled motor stator 100, asbest shown in FIG. 7, to form a complete-assembled motor stator inaccordance with the preferred embodiment of the present invention.Referring again to FIGS. 1, 2B, 8 and 9, the motor stator automaticallyassembling method in accordance with the preferred embodiment of thepresent invention further includes the step S8: automatically combiningthe printed circuit board 30 with the semi-assembled motor stator 100 byan auto holder unit (e.g. manipulator) 9 a to form a complete-assembledmotor stator. In a preferred embodiment, the pins 101 of thesemi-assembled motor stator 100, as best shown in FIG. 3, are insertedinto via holes of the printed circuit board 30, and the pins are furtherbent and moistened with solder paste for soldering the semi-assembledmotor stator 100 with the printed circuit board 30. By way of example,the printed circuit board 30 includes a plurality of contact points,including a first phase (U phase) contact point 30 a, a second phase (Vphase) contact point 30 b and a third phase (W phase) contact point 30c. In order to improve the assembling operation, the contact points ofU, V and W phases are provided with assembly marks shown at “U”, “V” and“W” on the printed circuit board 30 for perfect alignment.

Referring again to FIGS. 1, 2B and 9, the motor stator automaticallyassembling method in accordance with the alternative embodiment of thepresent invention further includes the step: automatically executing apower test, a resistance test, a dielectric withstand voltage test, aninsulation shock test or a load test on the complete-assembled motorstator 100 by second test equipment 9 b. Accordingly, thecomplete-assembled motor stators 100 are separated into two lines onwhich to convey qualified stator products and unqualified statorproducts.

Referring again to FIGS. 2A and 2B, the motor stator automaticallyassembling system in accordance with the preferred embodiment of thepresent invention selectively includes the pin insert unit 1, the feederunit 2, the wire-winding unit 4, the first assembly unit 6 a and thesecond assembly unit 7. In an alternative embodiment, the motor statorautomatically assembling system further includes the vibrator unit 2 a,the first conveyer unit 3, the second conveyer unit 3′, the thirdconveyer unit 6, the fourth conveyer unit 7 a, the punch machine 8, therotary unit 8 a, the first testing equipment 5, the second testing testequipment 9 b, the auto holder unit 9 a or other equipment.

With continued reference to FIGS. 2A and 2B, the first conveyer unit 3connects to the feeder unit 2 and the wire-winding unit 4 connects tothe first conveyer unit 3. Furthermore, the second conveyer unit 3′connects to the wire-winding unit 4 and the first assembly unit 6 aconnects to the second conveyer unit 7 so as to form an assembly line.

With continued reference to FIGS. 2A and 2B, the first conveyer unit 3connects to the feeder unit 2, and the wire-winding unit 4 connects tothe first conveyer unit 3. Furthermore, the second conveyer unit 3′connects to the wire-winding unit 4, and the first assembly unit 6 aconnects to the second conveyer unit 7, to form an assembly line.

What is claimed is:
 1. A motor stator automatically assembling methodcomprising: supplying insulation members by a feeder unit to a firstconveyor unit; arranging the insulation members on the first conveyerunit conveying the insulation members to a wire-winding unit; windingwires onto the insulation members to form wire-wound insulation membersby the wire-winding unit; supplying and arranging the wire-woundinsulation members on a second conveyer unit conveying the wire-woundinsulation members to a first assembly unit; inserting pole teeth intothe wire-wound insulation members to form a plurality of compact poletooth sets by the first assembly unit; and inserting the plurality ofcompact pole tooth sets into a stator ring frame to form asemi-assembled motor stator by a second assembly unit.
 2. The motorstator automatically assembling method as defined in claim 1, whereinfeeding the insulation members includes selecting the insulation membersby a vibrator unit while feeding the insulation members.
 3. The motorstator automatically assembling method as defined in claim 1, furthercomprising prior to selecting and feeding the insulation members,inserting at least one pin in each insulation member by a pin insertunit.
 4. The motor stator automatically assembling method as defined inclaim 3, wherein winding the wires onto the insulation members, furthercomprises winding the wires onto the at least one pin in each insulationmember to electrically connect therewith.
 5. The motor statorautomatically assembling method as defined in claim 3, furthercomprising bending the at least one pin of each of the wire-woundinsulation members to form a bent portion.
 6. The motor statorautomatically assembling method as defined in claim 1, furthercomprising executing an impedance or insulation test on the wire-woundinsulation members by a test equipment.
 7. The motor statorautomatically assembling method as defined in claim 1, wherein insertingthe pole teeth comprises stacking the pole teeth in a feed magazine andinserting the stacked pole teeth into the wire-wound insulation members.8. The motor stator automatically assembling method as defined in claim1, further comprising supplying the stator ring frame to the secondassembly unit by a third conveyer unit.
 9. The motor statorautomatically assembling method as defined in claim 1, furthercomprising rotating the stator ring frame with respect to the secondassembly unit by a rotary unit, thereby inserting each of the pluralityof pole tooth sets into the stator ring frame.
 10. The motor statorautomatically assembling method as defined in claim 1, furthercomprising combining a printed circuit board with the semi-assembledmotor stator to form a complete-assembled motor stator.
 11. The motorstator automatically assembling method as defined in claim 1, furthercomprising punching at least one surface of the semi-assembled motorstator to form at least one recession which is formed to combine thepole teeth to each other.
 12. The motor stator automatically assemblingmethod as defined in claim 1, further comprising punching at least onesurface of the semi-assembled motor stator to form at least onerecession which is formed to combine the plurality of compact pole toothsets with the stator ring frame.
 13. The motor stator automaticallyassembling method as defined in claim 1, further comprising executing apower test, a resistance test, a dielectric withstand voltage test, aninsulation shock test or a load test on the semi-assembled motor statorby test equipment.